#11  
Old 10-31-2010, 06:46 PM
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Location: Vancouver Island BC
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Default Re: Pompeii in Nanoose Bay!

Mortar Coat:
Since vermiculite will not get into the crevices/voids as easily, Dave wanted to put on another layer now. Using a high-strength mix (2:1, type S), he applied this all over the stucco wire using his notched trowel. High-heat mortar is not necessary at this point of course, although the mix is good for 600 degrees.

Rain forecast again, so we covered with poly and will hope for some dry time tomorrow.

Karen
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Pompeii in Nanoose Bay!-100_1451.jpg   Pompeii in Nanoose Bay!-100_1452.jpg  
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  #12  
Old 11-01-2010, 09:35 AM
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Default Re: Pompeii in Nanoose Bay!

Karen,
Your oven looks clean and sound - very nice. I notice some of the bricks in the arch required a face cut to achieve the desired taper. Did you use a 10" or 14" wet saw for this. I was planning on replacing my 10" saw with another 10", but am not sure it is capable of such a cut. Any input would be appreciated.
Thanks,
gene
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  #13  
Old 11-01-2010, 08:01 PM
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Default Re: Pompeii in Nanoose Bay!

Gene,
Thanks for the compliments - Dave says it is a 14" masonry saw which was only JUST big enough blade for the bricks, so 10" will be too small, I'm afraid.
Good luck!

Karen
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  #14  
Old 11-02-2010, 05:41 PM
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Default Re: Pompeii in Nanoose Bay!

Today, Dave continued the arch and vent for the chimney. He used more firebrick to continue the arch leaving the vent opening at the top. He bought 4 sections of 8” x 12” x 12” flue liner and installed the first section. He used regular brick regular bricks beyond the arch area.

Now I’m getting excited! It is beginning to look like something I can definitely cook-in as opposed to a scarily mammoth amount of masonry and concrete off my deck!

Karen
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Pompeii in Nanoose Bay!-100_1455.jpg   Pompeii in Nanoose Bay!-100_1456.jpg   Pompeii in Nanoose Bay!-100_1457.jpg  
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  #15  
Old 11-04-2010, 10:46 AM
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Default Re: Pompeii in Nanoose Bay!

Looking great Karen...your husband is quite the craftsman Do you know off hand what your final fire brick count was?
Thanks again,

gene
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  #16  
Old 11-04-2010, 12:24 PM
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Default Re: Pompeii in Nanoose Bay!

gene,
Altogether, we used about 200 firebrick; that includes the arches and around the vent throat. And despite careful cuts and skilled usage, there was still some waste.

Today, he is forming-up the enclosure so stay-tuned!

Karen
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  #17  
Old 11-07-2010, 02:27 PM
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Default Re: Pompeii in Nanoose Bay!

Enclosure:
So we’ve started on the enclosure. Although we have pretty much decided on the design (only while building the oven floor!), our inspiration is only a small picture sourced on the net of a WFO face-on, so we are having to work out the build based on our materials and the oven’s position, as we go. (I must admit, last week we did seriously consider leaving the oven in its round state. However, the chimney needs to double-back to avoid the beam and glass of the future deck roof so an enclosure is necessary to hide the ‘squirrel tail’ of the chimney.)

Originally, Dave thought that he’d build the enclosure using steel studs and cement board. Then he thought he might as well build it using brick and block since he has the materials and it’s easier for him to do. However, before he started, he had an idea; if he is going to mix insulating concrete using the perlite to fill the inside of the masonry skin, why not just use the mix to make the whole enclosure, at least up to the vent level? So he formed the shape, using plywood and studs, bolting wood to the block foundation using his Hilti gun, and mixed the insulating concrete, pouring it in several batches, up to the first flue liner, before the chimney will change direction. Took LOTS of batches and used the 17 bags of perlite we had left!

Karen
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Pompeii in Nanoose Bay!-100_1475.jpg   Pompeii in Nanoose Bay!-100_1464.jpg   Pompeii in Nanoose Bay!-100_1476.jpg  
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  #18  
Old 11-07-2010, 02:36 PM
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Default Re: Pompeii in Nanoose Bay!

Today, Dave removed the forms. He will be building the narrower upper layer out of brick, hopefully this week. The final exterior will be stone, by the way.

We have had a couple of small fires to start curing. We have alot of moisture in the oven so it will take a while to dry. Since Dave has yet to crawl inside the oven to fit the ash-dump, we have contained the fires in a foil pan so he doesn't come out full of soot. We have been absolutely thrilled with the draw of the smoke; even without the finished height of the chimney, there has been virtually no smoke out the front arch. Decades of building fireplaces have paid off!

Karen
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Pompeii in Nanoose Bay!-100_1477.jpg   Pompeii in Nanoose Bay!-100_1479.jpg  
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  #19  
Old 11-10-2010, 07:37 PM
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Default Re: Pompeii in Nanoose Bay!

Enclosure continued:
After stripping the forms, Dave continued the enclosure using brick, cutting the flue-liner to go backwards over the dome and then building it vertically. Since we have slanted sides for the enclosure, sort of a flat-topped pyramid, he staggered the brick courses until we had a suitable square dimension for the chimney cap. This cap will be formed and out of exposed concrete and will be approximately 3” thick with sloping sides for run-off with a top to prevent the rain from entering. Until that’s done, it will be temporarily covered with skagit, unless we’re using the oven (WF turkey this Christmas?!).

Once the brickwork was complete, Dave plastered the whole enclosure with a stucco mix to seal the WFO. He then made another curing fire - our 3rd, I believe, and it is drawing magnificently. Oh, and our ash-dump arrived so he was able to crawl in the oven and place it in the built-in space.

Since our company has a large brick project beginning shortly, Dave’s main concern was getting the WFO pretty water-tight and useable as the outer stone may not be completed for a few months.

Karen
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Pompeii in Nanoose Bay!-100_1481.jpg   Pompeii in Nanoose Bay!-100_1484.jpg   Pompeii in Nanoose Bay!-100_1487.jpg  
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  #20  
Old 11-10-2010, 07:41 PM
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Default Re: Pompeii in Nanoose Bay!

Decorative Arch:
A few weeks ago, Dave formed and poured a decorative arch of exposed concrete for the front of the WFO. Today, he cemented it to the front of the oven. Yay!!
Eventually, the stone will butt-up against it as will the concrete counter/landing pad that is yet to be formed/poured.

The cap for the chimney will be made the same way.

Karen
Attached Thumbnails
Pompeii in Nanoose Bay!-100_1438.jpg   Pompeii in Nanoose Bay!-100_1439.jpg   Pompeii in Nanoose Bay!-100_1458.jpg   Pompeii in Nanoose Bay!-100_1494.jpg  

Last edited by peterlyn; 11-13-2010 at 11:22 AM.
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